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Old 10-15-2003, 06:32 PM
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How thick (filler) is safe?

I know the idea is to use as little filler as humanly possible. And that is the approach I have been using. However; I have a problem area on my bed stake pockets that I am trying to fill.

I welded in a patch, but the surrounding area is not flat, therefore I couldn't create a flush surface without a nasty lip.

Unfortunately I don't have pictures so I'll do my best to paint a picture for you.

Take a piece of FLAT sheetmetal, put a dent about the size of a baseball in it that sinks about 1/4. Now cut out a 2x2" hole in the center of the dent. Now, without banging out the dent, patch the hole AND make it level with the surrounding metal.

So I just did my best to contour the patch into the dent, then I slapped bondo over the top of it. Just wondering how thick is safe...without it cracking out.

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Old 10-15-2003, 07:12 PM
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You really should not go over 1/8". More than that you stand a chance of cracking. Can you weld or drill and take a screw and pull the dent out some more. If not then I would use some Tiger Hair that has fiberglass strands in it then use something along the line of AllMetal to overcoat it. I have worked on cars that has had a 1/2" and more of filler and you could literally knock the whole piece out with a slight tap of a hammer. Go as thin as possible for best results.

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Old 10-15-2003, 07:36 PM
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Todays plastic fillers are so good it's amazing how thick you can really get away with. If your filling a area that isn't going to flex as you described a 1/2 to 3/4 inch would hold. I would suggest building with 2 or 3 layers instead of plowing in 1 batch. If your nervous use the "Kittyhair" fiberglass strands mixed in the first couple coats and let things cure completely. Sounds like your filling an area that will be solid enough to have no worries

I think Kevin45 and I were typing at the same time,,,lol I didn't mean to give a conflicting opinion, certainly thinner is better but there are exceptions as long as you know the risks.

Last edited by milo; 10-15-2003 at 07:36 PM.
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Old 10-15-2003, 08:05 PM
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The area I am talking about is the rear-most stake pockets on the bed of my truck. I think the other stake pockets will be a breeze to's these two (left and right) that are going to be a pain in the butt.

I don't think the metal is mal-formed, warped or damaged, but it is as I described. I'll have to take some pictures of the one I haven't started on.

I think I probably have maybe 1/4 of filler AT MOST on the one I already tried filling.

I'll definitely take pictures, it's too tough to put this into words.
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